Wire Arc Additive Manufacturing (WAAM): New Trends and Future Perspectives

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: closed (31 December 2024) | Viewed by 3095

Special Issue Editors


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Guest Editor
1. Department of Mechanical Engineering, Indian Institute of Technology Jammu, Jagti, NH-44, PO Nagrota, Jammu, India
2. Joining and Welding Research Institute, Osaka University, Osaka, Japan
Interests: welding engineering; process modelling; additive manufacturing

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Guest Editor
Department of Materials Engineering, KU Leuven, Campus De Nayer, 2860 Sint-Katelijne Waver, Belgium
Interests: additive manufacturing; solid-state welding; dissimilar metal joining; impact welding

Special Issue Information

Dear Colleagues,

Wire Arc Directed Energy Deposition (WA-DED), commonly known as Wire Arc Additive Manufacturing (WAAM), has emerged as a transformative technology in the field of additive manufacturing (AM), promising unprecedented opportunities for innovation in the production of metallic components. This Special Issue aims to explore the latest trends and future perspectives in WAAM, providing a comprehensive platform for researchers and industry professionals to contribute cutting-edge insights.

WAAM, characterized by its use of an electric arc as the heat source and a metal wire as the feedstock, offers distinct advantages such as high deposition rates, cost-effectiveness, and versatility in handling various materials. This Special Issue will delve into the recent advancements in process optimization, material development, and equipment design, addressing challenges and pushing the boundaries of what is achievable with this additive manufacturing technique.

Authors are invited to submit contributions (full length research articles, communications, or reviews) that highlight novel applications of WAAM across diverse industries, including aerospace, automotive, energy, and healthcare, thereby sharing their expertise and ultimately enriching the discourse on WAAM. This Special Issue will encompass a broad spectrum of topics, ranging from fundamental research on process parameters and microstructural evolution to practical considerations in real-world manufacturing scenarios. By bringing together diverse perspectives and the latest research findings, this Special Issue aims to chart the trajectory of WAAM's evolution and pave the way for its future integration into mainstream manufacturing processes.

Key areas of interest include, but are not limited to, the following:

Process Development: New processes, process hybridization, laser arc, plasma and multi-wire WAAM;

Advanced Process Control: Exploring intelligent algorithms and real-time monitoring systems to enhance control over WAAM processes, ensuring precise deposition and superior part quality;

Material Innovation: Investigating new alloy developments, hybrid material combinations, and the impact of microstructure on mechanical properties to expand the material repertoire for WAAM applications;

Multi-Material Printing: Examining the feasibility and challenges of multi-material printing with WAAM, opening avenues for complex, multi-functional components with diverse material requirements;

Industrial Applications: Showcasing successful case studies and practical implementations of WAAM in various industries, emphasizing efficiency gains, cost-effectiveness, and sustainability.

Dr. Abhay Sharma
Dr. Angshuman Kapil
Guest Editors

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Keywords

  • wire arc additive manufacturing (WAAM)
  • wire arc directed energy deposition (WA-DED)
  • welding-based additive manufacturing
  • laser arc
  • plasma
  • process optimization
  • material innovation
  • advanced process control
  • multi-material printing
  • industrial applications
  • microstructural evolution
  • future perspectives

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Published Papers (2 papers)

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Research

14 pages, 9446 KiB  
Article
Development of a NC-Controlled GTAW-Based Wire Arc Additive Manufacturing System for Using Friction Stir Extrusion Recycled Wires
by Gustavo H. S. F. L. Carvalho, Gianni Campatelli, Bruno Silva Cota, Davide Campanella and Rosa Di Lorenzo
Machines 2025, 13(1), 10; https://doi.org/10.3390/machines13010010 - 28 Dec 2024
Viewed by 914
Abstract
This study investigates the feasibility of using friction stir extrusion (FSE) recycled aluminum wires as filler metals for gas tungsten arc welding (GTAW) and additive manufacturing applications. A NC-controlled GTAW feeding system was developed to enable the deposition of these recycled wires. The [...] Read more.
This study investigates the feasibility of using friction stir extrusion (FSE) recycled aluminum wires as filler metals for gas tungsten arc welding (GTAW) and additive manufacturing applications. A NC-controlled GTAW feeding system was developed to enable the deposition of these recycled wires. The effect of cleaning the machining chips before the FSE process on the quality of the manufactured wires and the resulting welded beads was evaluated. Wires produced from uncleaned chips and cleaned chips were compared in terms of their external appearance, ductility, and the presence of porosity after the weld deposition. The results showed that cleaning the chips before the FSE process is crucial for obtaining more uniform wires with better ductility. Automatic GTAW deposition using cleaned wires resulted in significantly improved bead geometry, reduced external porosity, and overall better quality compared to uncleaned wires. However, both wire types exhibited internal porosity, with uncleaned wires showing the worst performance. The findings demonstrate the potential of using FSE recycled aluminum wires for welding and additive manufacturing while highlighting the importance of chip cleaning and the need for further optimization to minimize porosity in the deposited material. Full article
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17 pages, 15715 KiB  
Article
The Formation of a Low-Carbon Steel/Ni-Cr-W Alloy Bimetallic Material via Liquid–Solid Compound Casting with a Laser Assisted Solid Surface
by Serhii Salii, Leonid Golovko, Oleksii Kaglyak, Oleksandr Kapustynskyi and Nikolaj Višniakov
Machines 2024, 12(8), 522; https://doi.org/10.3390/machines12080522 - 31 Jul 2024
Viewed by 1269
Abstract
The aim of this study was to develop a new manufacturing process for bimetallic materials by combining laser treatment with traditional casting methods. This process involves laser-treating nickel alloy-grade UNS 6230 plates to create a regular macro-relief on their surface. These treated plates [...] Read more.
The aim of this study was to develop a new manufacturing process for bimetallic materials by combining laser treatment with traditional casting methods. This process involves laser-treating nickel alloy-grade UNS 6230 plates to create a regular macro-relief on their surface. These treated plates are then placed in a sand mold, and molten non-alloy steel (S235JRG2) is poured into the mold to create bimetallic layered castings. The experimental procedure focuses on optimizing the melt-to-solid phase ratios and pouring temperatures to achieve a uniform microstructure and strong mechanical properties in the bimetals. The produced bimetallic castings are suitable for applications in the oil refining and chemical industries and heavy machinery sector. The quantitative results indicate that the optimized process parameters lead to a high-quality transition zone with minimal defects, characterized by the diffusion of alloying elements from the nickel alloy to the steel. The microstructure, chemical, and phase compositions were evaluated using XRD and SEM with EDS, confirming the formation of a robust metallurgical bond. Key findings include a significant improvement in the hardness and strength of the transition layer, with the optimal pouring temperature being 1600 °C. The resulting bimetallic materials demonstrate an improved performance in demanding industrial environments. Full article
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